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Harbor Freight tool cabs, how I did mine

blasto9000

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Mar 20, 2011
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92
Location
Los Angeles, Calif.
The astonishing setups people have chronicled here inspired me to revamp my tool chest setup. Three of the 42-inch HF tool cabs have replaced my old setup of a 42-inch Craftsman Quiet Glide tool chest combo and a Costco 48-inch workbench with drawers. I never liked that Craftsman... it was just really poorly made and very expensive. Every time I looked at it I felt ripped off.

Sorry about the mess but it's still a work in progress. The cabs are mounted to a frame I made out of 80/20 extrusions. My floor has a steep slope to it -- the three cabs total about 11 feet in length, and the slope is over two inches. So on the original casters the cabs were all crooked and were prone to drift around the floor a bit when slamming the drawers open and closed, even with the wheels locked.

IMG_3761.jpg


The legs were all cut at different lengths (from 1.5 inch to 4.0 inch) to match the contour of the floor. 80/20 brand leveling feet provide fine adjustment. I used two feet between cabs to minimize torque load on the legs with unevenly weighted cabs. I KNEW I should have peeled the rubber pads off the feet first...

IMG_3763.jpg


The cabs and frame are all tied together using the holes where the original handles are supposed to go. Inserted the head of an M6 cap screw into the T-slot to accomplish this. There are four holes on both sides of the cabs, the inner holes are threaded M6x1.0, and the outer holes are just thru-holes in the sheet metal. I used the thru-holes backed up with fender washers and nuts on the other side. (My use of an M6 cap screw was incidental and not intended to be the same thread as the handle holes.) For some reason 80/20 doesn't offer a USS T-slot stud for this particular extrusion.

IMG_3752.jpg


Everything is super-tightly fitted and stable. SO nice to yank a heavy drawer and not have the cab roll into my car! (The verticals are short on purpose -- to accommodate the worktops. I've already designed the 80/20-to-butcher-block interface but haven't built it yet.)

IMG_3764.jpg
 
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The Frisco Kid

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Apr 20, 2012
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645
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Central Texas
Great work on this! for any GJ'ers that haven't seen or used 80/20, think of it as industrial strength grown up Erector Set! Funny enough, the company was founded by a gentleman named Don "Wood".

http://www.8020.net/

Could you post a parts list for the 80/20 that you used? We use 80/20 for tons of stuff at work on projects. I've already got my plans for my 80/20 workbench & testing table.... this would be PERFECT!
 

Boost Creep

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Feb 17, 2010
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Location
michigan
wow, thats awesome! i might have to do something similar soon when i get around to putting together my bench. always wondered where to get that stuff
 

The Frisco Kid

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Apr 20, 2012
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645
Location
Central Texas
How is the quality on those cabinets? Apologize if the topic has already been beat to death... lol.

This has been beaten to death:lol:, but no worries. These cabs are outstanding in quality vs. cost. They aren't a KRL series box, but they are quite good and less than 10% the cost. For daily heavy industrial use, they might not cut it (although, I'm sure they would hold up in most auto shop/stereo shop applications) but for home shop/garage use they are outstanding!
 

Mandres

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Jun 22, 2006
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1,152
Great idea on the extrusion. I've been seeing that stuff pop up everywhere lately. How sturdy does it feel? I imagine 3 of the cabinets fully loaded would be a hell of a lot of weight. Any concerns about the aluminum frame holding up?
 

djd99

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May 4, 2009
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1,006
Location
Owosso,Michigan
Very nice and just plain looks clean. When you get the top on that's icing on the cake. By the way what size 80/20 is that.
 
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blasto9000

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Mar 20, 2011
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92
Location
Los Angeles, Calif.
Thank you guys, for the kudos.

If you've never worked with 80/20 before, I highly recommend going to their site to watch all the tutorial videos and download the catalogs. It's a very clever product but the hardware isn't intuitive, at least not to me.

80/20 has an eBay store and an Amazon store. To me the Amazon store is more convenient, but the Amazon shopping cart has a limitation on how many items it will hold. If you order 100 screws, they're stored in the cart as 100 individual items.

The T-slot extrusion is not very expensive, but you still need to be careful when designing a project because the cost of the joining hardware can really get you. I find the easiest way is to casually design the project, and then re-do it to minimize parts count.

Originally I was going to build the rack out of hot-roll steel and weld it together. But the cost of the 80/20 extrusion is about the same and the 80/20 is a LOT easier to work with and more versatile. (Plus, if you make a mistake, you can just unbolt it and re-do.) I did all the cuts with a Rage cutoff saw, which is visible in the picture.

Here's my bill of materials:

1010 extrusion, 96", 8 pcs.
1030 extrusion, 36", 1 pc.
6-hole joining plate p/n 4166, 6 pcs.
End fastener p/n 3681, 12 pcs.
Leveling foot p/n 2192, 12 pcs.

1/4-20 x 0.5" BHSCP, (a lot)
Economy tee nuts (a lot)
M6x1.0 cap screw, 12 pcs.
M6 nuts and washers, 12 pcs.
1/4-20 plug tap (2 flute), 1 ea.

I hope it's apparent that I baked my noodle trying to minimize the parts count.

The construction is basically three 42x18" rectangular hoops that the tool cabs sit on. These are held together using end fasteners.

The hoops sit on the legs, which are 1030 extrusion (1x3" cross section). The hoops have a screw going through them radially and attach to axially drilled/tapped holes in the legs.

The hoops are 1" extrusion, two of them each, sitting on 3" extrusion, which leaves 1" in the middle. This is where the vertical members are joined and covered by the 6-hole joining plate.

Order of assembly:
Build 42x18" hoops, cut legs, drill/tap legs, and assemble into the base frame.
Install rear (wall facing) uprights with M6 studs protruding.
Level rack to the floor.
Take a leak, so you don't piss your pants during the next maneuver.
Empty tool cab and lay on the frame using armstrong method.
Slide tool cab onto the M6 studs.
Install front vertical member.
Rinse, repeat.
 
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cegreen

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Feb 27, 2010
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63
Location
New Jersey
Looks great! I have a sloping floor, too (idiots!), so I have the same problem. If you don't mind me asking, what was the total cost of the 80/20 parts? Thanks for posting this!

-Chris
 
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blasto9000

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Mar 20, 2011
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Los Angeles, Calif.
Let's call it $400 with tax and shipping.

$96 for the feet (8 ea @ $12 = $96)
$224 for the 96" extrusion (8 ea @ $28 = $224)
$43 for the joining plates (8 ea @ $5.40 = $43)
Approximately $25 for the screws and other fasteners. Have to give you an estimate there because they came from shop supply.

I came up with the original design (in my head) while sitting in classic Los Angeles traffic, sketched it when I got home, jotted down a bill of materials and costed it. 800 smackers! After a few more rush hour trips I figured out enough parts reduction to cut the cost by two thirds. Then to make the product a little higher grade than "barebones," I added a few more parts back, e.g., using the 80/20 feet because I liked them, rather than using cheaper shopmade feet.

Then I hemmed and hawed for a few days about spending $400 on another needless DIY project.

Took about a day, day-and-a-half of combined effort to empty out the tool cabs (for mounting) and then put everything back after mounting.

Cutting, drilling, tapping and assembling the extrusions took about three hours. I used the mini mill to drill a few of the holes, but the only tools really needed were bubble level, tape measure, Sharpie, cutoff saw, cordless hand drill, drill bit, 1/4-20 tap, and T-handle Bondhus balldriver. The stuff is really easy to work with.
 

PoorOwner

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Feb 10, 2007
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CA
How about get a long slab of butcherblock with grooves cut in between to make one flat maple top.
 

metaleltr

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Sep 4, 2009
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Location
Western Ohio
In business, the 80/20 theory is a powerful tool. This theory is called Pareto's Law after Vilfredo Pareto (1843 - 1923), an Italian economist and sociologist who said that 80% of your results come from 20% of your efforts. We run our organization this way and everyone shares in the advantages.
Our company name came from Pareto, our company philosophy comes from an ancient Chinese proverb:

"There is a man in the world who will never be turned down... he is the man who delivers the goods."
 

losttechnician

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Joined
May 13, 2012
Messages
34
Location
Texas
Looks like a lot of thinkum went into that, very nice! I was intending to build a square tube frame around a couple of metal cabinets to use as a reloading bench, but this idea looks way better, and I like that it can be disassembled if need be.

Thanks for the idea! (yes I am going to steal it)
 

stormin

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Sep 18, 2011
Messages
154
Location
Havana, FL
how do you open the drawers by the garage door track? looks like you can only get them open a few inches. you are a fab guru with your design. keep doing things to keep us dreaming about our own projects.
 

angzt

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May 20, 2012
Messages
31
Location
NJ
I'm an aircraft mechanic and I roll one of these boxes across the hangar floor everyyyyyyday. For what I paid for it, It's a decent little box. My only gripe is the drawers DON'T LOCK. It's such a pain in the *** for someone who is constantly rolling it around.
 

machine_punk

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May 14, 2011
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Location
Napa Valley, California
That is a very clean-looking installation! Looks very professional. That's a little on the steep side for price, but it is a once-in-a-lifetime purchase and makes your life easier every day.

I personally chose not to go with the HF 13-drawer units. While their quality is fabulous for the price, the drawers are just not wide (?deep...the distance between the drawer front and the back of the drawer) enough for me. In the end, I'll probably end up fabricating my own drawers and cabinet (but sheet metal is what I do).

Great job man...that setup is going to serve you well for a long time.

M_P
 

Trucky

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Apr 26, 2011
Messages
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I'm an aircraft mechanic and I roll one of these boxes across the hangar floor everyyyyyyday. For what I paid for it, It's a decent little box. My only gripe is the drawers DON'T LOCK. It's such a pain in the *** for someone who is constantly rolling it around.

I'm thinking two brackets near the end of the box, one on top and the other opposite, with a metal bar (With two bends and a 90* handle on top) that could be in an "open" or closed position. Pretty easy to rig up with the right tools. You could just turn the handle to "open" and the bar would swing clear of the drawers.

Sort of like this:

(handle)
_
-L (bend)
--|------------------------------
--|-----------------------------
--|------------------------------
-T(bend/end of bar)

Like this: http://keysolver.com/keysolver/MultiLockLockingBars.html but a bit dumbed-down.

You'd have to rig up your own detent system, but I bet a nice spring would do you very nicely. It would look like hell, but the drawers would stay shut when you want them. The detent is so you don't need to reattach a lock every 5 minutes.
 

The Frisco Kid

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Apr 20, 2012
Messages
645
Location
Central Texas
Did you consider using 1001 or 1003 for the extrusion pieces? We have some here at the shop, and I don't think that it would be too difficult to use one or the other to give the front a very flush look.

Also, having built it now, do you think that you could have used t-slot bolts rather that drilling/tapping?


Just some ideas that are rumbling through my head, I'd love to get your thoughts. Any ETA on the tops? I am floored with how impressive this build looks. VERY well done, again!!
 

Drewstang

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Dec 24, 2008
Messages
142
Location
Bedford, KY
We use 80/20 at work to build pnuematic rigs, work benches, test carts, and desks. My desk I'm sitting at now has a 80/20 frame and composite top. I never thought to use it as a box frame, lol.
 
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blasto9000

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Mar 20, 2011
Messages
92
Location
Los Angeles, Calif.
Did you consider using 1001 or 1003 for the extrusion pieces? We have some here at the shop, and I don't think that it would be too difficult to use one or the other to give the front a very flush look.

Also, having built it now, do you think that you could have used t-slot bolts rather that drilling/tapping?


Just some ideas that are rumbling through my head, I'd love to get your thoughts. Any ETA on the tops? I am floored with how impressive this build looks. VERY well done, again!!


Actually, I did consider using 1001 extrusion for the non-structural portions, but mainly for cost reasons (1001 is like half the price of 1010). But in the end I decided to use 1010 because I wanted all the extra T-slot to use for bench clamping. I plan on framing the worktops in a combination of 1010 and 1030 so I can clamp on a vise, grinder, arbor press (etc)... and then remove/store it after the job is done. That will also put a median between the worktops, which will be three separate pieces. I figured butting three worktops together successfully would be beyond my woodworking capabilities.

I suppose I could have used fastening methods for the extrusions, but drilling/tapping was the least expensive. It definitely would have been faster and more convenient to use the purely bolt-on joining methods though.

The worktops should be finished in early September. In addition to a day job I volunteer as a tutor at the Skid Row homeless shelters (and others), I'm getting a business off the ground with two partners, and I'm studying to take the project management professional ("PMP") certification exam. You should see my calendar, it reads like a work breakdown structure for building an aircraft carrier. (P.S., the little girl in my avatar is one of the kids I tutor.)
 
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